Method of molding composite-cork bodies



Oct. 30, 1928.

W. F. GRUPE METHOD OF MOLDING COMPOSITE CORK BODIES Filed Aug. l0, 1923 2 Sheets-Sheet 2 1 N VENTOR l .9,

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Patented. Oct. liti, 1928.

UNTED STATES PATENT FFCE.

VIELLIAIVI F. GRUFE, OF LYNDH'URST, NEV ERSEY, ASSG-NOR T0 BOUCHER CORK COM- PANY, OF NEW YORK, N. Y., A CORPORATEON OF NEW YORK.

METHOD OF MOLDNG COMPOSITEORK BODIES.

Application led August 10, 1923.

This invention relates to molded cork and the method of producing` the same.

Heretotore, it has been proposed to compress within niolds granulated cork or other particles ot cork waste and subject such molds in ovens to elevate l. temperature 'to approximately 600 F. to form products having; the shape ot the molds'. However, in suoli procedure, the cork mold is open to the air and at pressures at or exceeding atmospheric pressure, thereby permitting partial combustion to take place, resulting` in charring^ and other breakdown of the cork cells and rende?.1- ing' the cork brittle and oi reduced insulating quality.

Pursuant to the present inif'ention, the granulated natural cork or like cork waste is raised in temperature to approximately 3500 F., but under a vacuum to provide a pressure considerably lower than atmospheric pressure and toremove sul'istantially all air or other oxygen-contir-.lining` gas from Contact with the cork. Under such conditions ot operation, the temperature ot the heating' medium applied eXteriorly of the container enclosing); the cork is approximately 350O l?. which may be readily furnished by llames of ordinary so-called city gas. Upon attaining surh temperature and reduced pressure throughout the cork particles, l have discovered that the natural resins normally present within the cells of the cork enude through the walls o't the cells and in the absence oi" air or other oxygen;ontaining gas the cork resolves into a pasty mass without any subA stantial chemical decomposition or carboni- Zation and with a minimum loss ot natural resins. Pursuant to my invention, in the event olf greater loss ot natural resins or insu'thcient presence of natural resins in the cork, the desired proportion oit resin in the resulting' product is secured by charging; resin during' the operation. Similarly, other binders such as casein. may be added ior the particular purposes of the final product.

The resulting; mass may be transiter-red by suit-able means, under vacuum conditions, to molds 'tor shaping` the mass to the desired toi-ms and upon cooling` and exposure to ordinary atmosphere, the material or' the molded product closely resembles natural cork in its well known characteristics of appearance, lite and resiliency, also in high res ance to conductivity oit heat and cold, in high elec trieal resistance and in the property oli' repeh Serial No. 656,744.

ling moisture, water or like liquids. lfhe resultino; product is superior to natural cork in that it is oit' uniform structure and with the absence of pores.

Other features and objects o the invention will be more readily understood from the tol lowing detail description and the accompanving` drawings, in which u Fig. l illustrates diagrammaticaily a drum tor receiving the cork particles, a continuously acting pump and a condenser for creatn ing` a vacuum within the drum and for withdrawingmoisture and any oxygen-containing gases from the interior ot the drum; means itor withdrawing the heated mass from 'the drum into a mold, also mechanism for continuously compai ting the heated mass in such mold and suitable heating` means tor the drum, the Mwithdrawingmeans and tor the mold.

Fig. 2 is a cross-sectional view of the pinne'- cr on line 2-2 of Fig. l; L'

Fig. 3 is a similar cross-sectional view on line of Fig. l;

Fig. a is a perspective view of a product in the 'torni ot a pipe or round tube;

Fig. 4 is a detail view Ot a pair of interlocking,` pipes;

.F 5 is a perspective view of a squ are tub-e suitable `for hollow block construction, for walls and like uses;

Figi'. 6 is a detail top plan view of the .individual .molds and discharge 'from the drum ior chargingthe molds;

Fig. 7 is a 'liront vert-ical elevation ot the molds o1" Fig. 6; this tigure also shows its iront portion broken away to bringl to View otherwise hidden parts;

Fig. 8 is a sectional view en line SMS ot Fig. G;

Fig. 9 a sectional view on line 9--9 of Fig. 6;

Fig'. l() is a det-ail perspective view oit' indiridnal molds tor elbows; and

Fig. ll is a front elevational view of a molded halt of a cork elbow.

Referring to the drawings, the drum l is shown as cylindrical in outline and provided with a jacket 2 encircling` the cylindrical face and the opposite 'fiat end faces of the drum, Ytor receiving a suitable heatingl luid such as oils resisting decomposition at the maximum tenn'ierature of operation.

The heating` iiuid is elevated intemper atnre by means of the burners 8 which may be located closely adjacent the drinn, or the tluid may be heated in a boiler at a distance irom the drum and suitably connected with the jacket 2.

Under a suitably low vacuum, such as approximately within the range oit' from 25 to 29 inches ot' n'iercury column, and a heating temperature of approximately 350C F. tor the heating Huid, the cork is raised to a temperature equivalent to approximately 600 l1, under normal atn'iospheric conditions for cork ot certain water content; upon i'further reduction ot the temperature and increase ot vacuum the mass is rendered plastic and the plasticity and elasticity ot the resins as w ll as their binding qualities are maintained at maximum.

The cork is charged into the drum through the opening le, which isprovided with the closure sealed by clamps or other suitable means.

Leading from the interior ot the drum 1 is the pipe 6 connected to the condenser 8 and pump 7 tor the purpose ot' condensing the vaporized contents of the cork mass.

1;)1e1ei'ably, the drum 1 is equipped with a stirrer, such as the spaced spiral arms 9, 10 mounted on the central shatt 11 journaled at one end 12 interorly ot the drum 1 and at the other end passing through the sealed bearing openings 1S, 14; such as stuiiing boxes or other approved means. The gear 15 is keyed to the shaft 11, and meshes with the driving gear 1G, keyed to the shaft 17, carrying the driving pulley 18, for receivingl a belt or otherwise driven by suitable driving means.

4At a suitable location in the wall ot the drum 1, is arranged the discharge passage 19, having a gate 20, opeiated by the handle 21. The discharge pipe 19 extends prei"- erably downwardly to con'ununicate with the mold.

The mold may comprise an interior section 22, subjected to heat furnished by the series ot burners 23 or by means of a heating `fluid, asaioresaid, and comprising also a posterior section 24 provided with the jacket 25 tor reducing the temperature oit the mold section 24.

In advance of the mold section 22 is arranged the passage 25', enclosing the plunger 2G for advancing` and compacting the mass in the mold section 22 upon discharge from the passage 19. rllhe plunger 26 is reciprocated by the pitman 27, eccentrically pivoter to the gearl 28, driven by the worm Q9, from the driving shaft 17, or suitable equivalent means.

In Fig. 7, the mold is illustrated 'for the production of pipe or round tube 39 and tor such product, see Fig. 4L, the central opening 39a is detern'iined by the round rod 3() serving as a core. The rod 39 is centered at its rearward end with the opening 31 passing through the plunger 2G, and anchored in the block 32, secured within the passage 2h by means ot the set screws 323, 523, see also lig. il. rlhe iorward end oi the rod 3U is loosely received within the perforation 3l in the scalingl plug 35. rEhe plunger 2() is cut away as indicated at 236 for a distance correslpionding to the stroke ot the plunger 2G under rcriprocation by the pitman 2T.

rl`heplug 35 serves as a seal within thel mold until the mold has become automatically sealed by the molded cork mass injected therein by the plunger 2o, and itor such purpose the plug lo closely lits the inner tace ot the anterior mold section 22 and the, posterior mold section 2l. For the `successive positions of the sealing plug 3:3, it serves4 as an abutment tor the mass ot molded cork which is subjected to repealed impactingl by the plunger 26, and upon accretions ot plastic cork added upon discharge through the pipe 19 upon successive withdrawals ot' the plunger 26, the increasing, compacted molded mass causes the sealing plug 55 to gradually advance along the mold sections 22, iat, until the plug 35 reaches the linal mold Bti, having au enlarged diameter as compared with the diameter ot the mold section 24T.

rllie linal mold section 3G may be ol1 slight outward taper or gradually enlarged in crosssection to reduce the wall triction olf the molded cork mass while the molded cork mass is being transmitted through the linal mold section 3G.

It will be observed that as the plastic mass is compacted withiii the mold in more or less solid term, it is automatically removed 'troni the ejtl'ect ot the vacuum created by the pump 7 and its temperature ellectually reduced trom the equivalent temperature ol ooo" l under the vacuum to a temilierature of approximately 3500 l. at a pressure approximating one atmosphere whereby the molded cork mass is autonnitically reduced in temperature without exposure to the air.

The cooling jacket produces a tui-ther reduction in actual temperature ot the molded cork product to enable the product to be cut, as by the rotary knii'e 2li, in the open air without substantial change in the cork mass.

rllhe resulting cork product has thc torni oit the mold Q2, and is comprised ot portions bound to one. another by the sell-contained resins. rltlie cork product is tree l'rom pores such as is present in natural cork.

The cork product possesses the advantageous Yfeatures oit natural cork ot resiliency, ot' the capability oit being reduced in volume under pressure and automatically restoring` itself to original volume upon release oi' pressure.

yThe product in the 'l'orm o t' a pipe or round tube 39 is eminently adapted as an insulator for retrigerating systems, as by slip-ping such tubes over the pipes. The round tube 39 of molded cork may itself be employed as the pipe.

To further insure insulation at the joints of the successive molded cork pipe sections, the opposite ends of the pipe sections are provided with male projections 38 and female avities 38 respectively, such as conical in formation an d v: ith or Withou t the appli cation of a water and air proof adhesive, whereby the joints between the successive pipe sections f are interlocked to preclude water and air leakage.

TVhere 'the product is desired for electric insulating purposes, the mold is shaped accordingly. .lhe length of the molded pipe sections may be varied as desired by providing the mold of corresponding length.

By the aforesaid procedure, the bonding of the resulting molded cork mass is attained by the resins present in nature in the original cork. lf it is desired to increase the resin content, additional resin is charged through the opening Ll of the drum l, when charging in the cork granules or Waste and for such purpose, rosin or other resins or oils closely similar to the natural cork resins are preferred. Such increased resin mass possesses increased Waterproofing qualities.

My method is also applicable for forming gaskets of the resulting molded cork by providing molds having the outline of the desired gasket and cutting the molded mass into sheets or thicknesses corresponding to that of the desired gasket.

ln a similar manner, pipe fittings, such as elboivs, Ts and the like may be formed in molds of corresponding` shapes.

ln Figs. (i, 7, 8 and 0 I have illustrated a set of molds and operating` mechanism therefor, in conjunction with the plastic-renden ing apparatus illustrated in Fig. l of the drawings, for the molding of elbows, Ts and the like of plastic cork. rl`hus, as is indicated in Fig. 6. upon the delivery of plastic cork material through the discharge passage 19, into the posterior discharge passage d0, ending horizontally and corresponding to the anterior mold section of the ar 'angenient shown in Fig. l and similarly provided with the coinjjiacting plunger 26, the plastic mass Lil, see Fig. G, is forced by a plunger 26 through the outlet 42 into the cavity of a mold all, brought b v suitable mechanism (described more fully hereinafter) into register with the outlet a2, whereby the material is fed into the interior of such mold i3 and is impacted upon the reciprocation of the plunger 26. In this instance, the plunger 2G, may be solid, that is to say, Without any perforation such as the perforation 34s and no rod such as the rod for guiding the plunger 2G or for forming a core in the impacted mass, is required.

Upon the delivery of the proper amount of compacted plastic cork into the mold 43, the succeeding mold is then brought into register With the outlet 42, and the plastic mass under similar condition impacted therein.

The mechanism of the set of molds may be of any suitable form. ln Figs. 6, 7 and 8 I have illustrated the oppositely disposed guide plates Jl/l1, d5, extending vertically from and secured to a suitable bed d6. The molds ii3 are duplicate, and arranged in side by side male and female relation between the vertical guides lill, l5 and the bed d6. The feeding of the molds i-3 into register with the d ischarge mouth Ll2 is effected by means of the feed plate a7 operated by the pitnian atl connected with the cam i9, on the shaft 50, in suitable intermittent gearing relation with the aforesaid operating mechanism of the plunger 26 as is illustrated Fig. l5 the shaft may be manually operated if so desired. Suitable means is provided for interconnect1 ing the plunger 2G operating mechanism and the mold advanciiig and locating mechanism, to properly time the mold advancing mechanism and plastic cork feeding mechanism with one another.

Preferably locating means 5l is provided for determining and for holding in position each mold i3 in register with the mouth. of the outlet 4t2 of the discharge passage llll; such locating means may comprise the center- .ing pin 52, see Fig. 8, having a handle 53, the end 5d of the pin .52 being tapered for facilitating entry and release With respect to the opening in a side of the mold 43.

A suitable form of interlocking male and female mold sections 4-3, 43, is shoivn in Fig. l0, and comprising a suitable cavity 56 on one face of the mold and a suitable projecting 58, see also Fig. '8, serving as a core for the cavity 57 of the succeeding mold 4:33. Upon lilling the cavity 56, 56=L of any pair ot' such molds 42?), .13 by delivery of the molded cork through the mouth 57, see also Fig. 9 of the mold, 'the plastic cork takes the shape of a halt' elbow 59 as is illustrated in Fig. ll, i. e., the formation determined by the conjoint position of the projection 58 serving as a core Within the mold cavity 5G.

For other shapes of molded cork tittings the molds are formed correspondingly and similarly fed in proper relation to the discharge outlet Zl2 of the drum.

Preferably, the molds 43, liza are subject to vacuum condition prior to being brouuhi: into register with the discharge outlet of the drum l, and a convenient arrangement therefor comprises the upper Wall 60, see Fig. 8, making a closed run-Way with lthe bed and With the side plates ela. d5, the runway being effectnally sealed automatically at its ends by the snug lit of the sides of the molds With the bed d6. upper Wall G0 and side Walls 44, 45. The sealii 3,' effect may be further insured by spriiig-actuated gasket strips lo catcd in alignment with one another on the inner faces ot the top 60, bed titl and sides lb l5, to t'orm a virtual square collar, such collars being located ii spaced relation with in the run-way, and engaging the outer sides of the molds to further secure the sealing eticct to provide the vacuum condition within the run-way.

'llo bring about the vacuum condition, the run-way is coi nectcd by suitable means with the exhaust pump 7 as by providing the slot 64 in the side wall lr-sl, Figs. o T) over which extends the nianilold 62 connuunicatincgthrough the pipe 63 with the suction line ol the pump 7. The interior 6l ot the manifold G2 communicates through the slot Gl vith the inlet openings 51 of the molds 43" locatetL anterior ot' the outlet 4Q, wherebyY the interior or cavities 56 ot the molds prior to being` brought into register with the outlet 4t2 and during the period et register are under vacuum condition.

By the procedure ot my invention or subjecting` the cor r particles to the elevated tem* perature as above described in the` drum l. or equivalent7 the cork particles are permitted tree expansion. which is enhanced by the condition of the Vacuum created by the pump supplemented by the condensation by the condenser 8 ot the moisture and volatile constituents ot the cork.

Upon completion ot he heating stage in the drum l or equivalent, the cork particles lose their tendencyv to expand and assume the property of contracting which properlyl continues during the compression and molding stages7 thereby facilitating the compression of the molded product, the progress of the molded product through the mold and the discln oit the molded product 'trom the mold, thereby obviating` the necessity ot' cnlarg'ingi the final mold section or the discharge opening ot the mold.

My invention is accordingly advantageous tor the treatment ot soallcd green cork which by inv herding;- treatment under the condition ot tree expansion eliniinates all tendone;7 ot' the green cork to expand while under the subsequent stages ol molding and d i sch ar A torni of hollow block ot' the molded product 65 produced as herein above described illustrated in Fic. Such block oit hollow cork secures improved cold insulation b v reason ot the dead air space G6 coinpared with cork board and is sui'ieriorli7 adagted for use in lieu ot cork board. Thus, in walls7 tloors. ceilings or roots ot refrigerator plants. such hollow cork blocks ari` interposed between the brick or other buildingl inateriah and are applicable in buildin;x` con# struction generally. The in'iprored hollow block secures incr ased insulatioi heat and against transmission ot' sound.

1d/vhereas l have described my in "cntion by and afrainst reference to specific lorms thcrcot` it will be, understood that man)` changes and inodilica tions may lic mad(` without departing Ylrom the spirit ot the invcnlioin as dclincd lrv the appended claims.

I claim:

l. The process ot formingY molded products ot cork, comp-risinu1 subjectingA ;'ranuics ot cork to au elevated ten'iperaturc in a par tial vacuum to render the cork and thc resins natural in cork plasti f and molding thc same while in plastic form under vacuun condition.

2. rlhe p 'ocess o'l'V ito-rniinc molded prod ucts of cork, comprising subjecting granules ot cor i to an elevated temperature in a \'acumn to render the cork and the resins natural in cork plastic and molding` the same whi lc in plastic torni and in substantial abscncix oll oxidizing c ndition.

3. The process oli producing molded compositie cork bodies7 comprisiirgv heating' comminuted cork in a. closed chamber at reduced pressure and transterring the heated imiterial to a point where it is moldcd whilc cxcludingg' air :trom and preventingl comlaif-tion oli the heated material.

et. The process ot formingY molded products trom cork particles, which comprises subjecting cork particles to an elevated tcmperature in a vacuum and in the presence ot resinous niaterial. to render the cork and thc resins natural in cork plastic and moldingthe same while. in plastic lorm and under vacuum condition.

5. The process ot forming molded products trom cork particles, which comprises .subjecting cork particles to au elevated tcmpcrature in ay vacuum and in the pre--=cmc ol reninous material, to render the cork and the resins natural in cork plastic and modinu` the cork while in plastic l'orm under thc condition ol5 exclusion ol'Y air.

6. The process ot producing molded cork bodies, comprisingl chargingt comminuttal cork into a` receiver, hcatingr the unile 'inl therein and meantime applyingv snel ioi to the` receiver to cxhaiist, ai-r and other dcrcl-'ipcd agitating` the heated cork` divcliartingf; the resultant plastic mass into a molding; :conc and meailtime excluding air thcrcl'rom. molding` the material and discharging' it I'rom the molding# zone. i

T. The process which comprises charffjinf'; particles ot' cork into a` suitable rcccivcrfsubjecting the interior olE the receiver to an cicrated temperature and removing` air thcretroni. agitatincl the heated cork particles. renderin the cork and the rcsinf` natural in cork plastic. dischareinov thc reeadtinew plas tic mass under heated condition and in substantial absence otA air into a` mold. rcmovincj the filled mold and supplying4 an additional `iliold to thc point oli discharge ol' the rcccivcr and cooling;l the successively lillcd molds.

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meetelt 8. rThe process which comprises charging particles et cork into a suitable receiver, subjecting the interior ot the receiver to an clevated temperature and in a partial vacuum, agitating the heated cork particles, rendering the cork and the resins natural in cork plastic, discharging the resulting plastic mass under heated condition and in a vacuum, into a mold, removing the lilled mold and supplying an additional mold to the point ofdischarge ot the receiver and cooling` the successively filled molds.

9. The process which comprises charging V)articles oi? corr into a suitable receiver, subjecting the interior oi: the receiver to an elevated temperature and in a partial vacuum, agitating the heated cork particles, rcnilering the cork and the resins natural in cork plastic, disclnrrging the resulting plastic mass under heated condition and in a. vacuum, into a mold', removing the Vhlled mold under vacuum condition and supplying an additional mold to the point of discharge of the receiver and cooling the successively lilled molds.

10. The method of producing molded products of corks, which comprises withdrawing moisture inherent in cork particles by subj ecting the cork particles to an elevated temperature under the condition ot 'free expansion and low pressure and thereailfter subjecting the heated cork particles to molding` compression while excluding air from and preventing combustion thereol".

ll. rlhe method of producing molded products of cork, which comprises withdrawing moisture inherent in cork particles by subj ecting the cork particles to an elevated temperature and agitation under the condition of i'ree expansion and low pressure and thereailfter subjecting the heated cork particles to molding' compression while maintaining low pressure condition and preventing access oit air to the material.

l2. The method ol producing molded products oil cork, which comprises withdrawing moisture inherent in cork particles by subjecting the cork particles to an elevated temperature to render plastic the cork particles under the condition of free expansion and thereafter subjecting the heated cork particles to molding compression under the condition oit a vacuum.

13. rlhe method oit producing molded products o'l cork, which comprises withdrawing moisture inherent in cork particles by subjecting the cork particles to an `elevated temperature to render plastic the resins natural in the cork particles under the condition ot free expansion and thereafter subjecting the heated cork particles to molding compression under the condition of a vacuum.

la. rl`he method of producing molded products oi" cork, which comprises withdrawing moisture inherent in cork particles by subjecting' the cork particles to an elevated temperature in a vacuum under the condition et tree expansion and thereafter subjecting' the heated cork particles to molding compression under the condition oli a vacuum.

l5. rlhe method. oi? producing molded preducts of cork, which comprises withdrawing moisture inherent in cork particles by subjecting the cork particles to an elevated temperature and agitation in a vacuum under the condition ot free expansion and thereafter subjecting the heated cork particles to molding compression under the condition ot a vacuum.

16. rllhe method of producing molded products of cork, which comprises withdrawing moisture inherent in cork particles by subj ecting` the cork particles to an elevated tem-- perature to render plastic the cork particles in a vacuum under the condition oi vfree expansionand thereafter sul'ijecting` the heated cork particles to molding compression under the condition of a vacuum.

17. rThe method o' producing molded products o1 cork, which comprises withdrawing moisture inherent in cork particles by subjecting the cork particles to an elevated temperature to render plastic the resins natural in the cork particles in a vacuum under the condition ot -liree expansion and thereafter subjecting the heated cork particles to molding compression under the condition ot a vacuum.

lin testimony whereof l have signed this specification this 9th day of August 1923. 

